Constructional finish detail element



April 11, 1939. A. DOHERTY 2,154,036

CONSTRUCTIONAL FINISH DETAIL ELEMENT Filed Aug. 25, 195'? Ea. Z.

INVENTOR. APT/9M? 006 567) I? :5 2k

ATTORNEY.

Patented Apr. 11, 1939 UNITED STATES PATENT OFFICE 4 Claims.

This invention relates to finish detail for building construction, andhas for an object the provision of a surfacing panel of novel and highlyadvantageous design.

A more detailed object is to provide a panel susceptible to fabricationin any suitable size and adapted for insulation in the place of drainandsplash-boards, fioor, walls, and other surfaces more conventionallyconstructed of tile, sheet metal, wood, or cementitious material. Withthis object in view, the present invention comprises a novel,highly-decorative, and thoroughly sanitary drainand splash-boardconstruction, or a wall or floor construction wherein absolutewaterproofing and sanitary protection are desired, as in bathrooms andshower stalls. It becomes apparent, therefore, that I have provided asubstitute for the tile, Monel metal, or stainless steel now popularlyused for the types of finish installation recited.

A further object of the present invention is to provide novel and highlyefiicient attaching and supporting means for the panel, whereby warping,sagging, and other distortion of the installed panel are effectuallyprevented, particular attention having been paid to the prevention ofthe buckling or blistering produced by the application of heat,especially when unevenly applied, which represents one of the mostpronounced disadvantages of monel or stainless steel drainboards.

Another object is to provide a construction finish detail element of thegeneral character indicated which is relatively simple and inexpensiveto manufacture and install and which is generally superior in efiiciencyand serviceability.

A still further object of the present invention is to provide a novelmethod of constructing the finish detail element referred to.

The invention possesses other objects and advantageous features, some ofwhich, with those enumerated, will be set forth in the followingdescription of the preferred embodiment of my invention illustrated inthe drawing accompanying and forming a part of the specification. It isto be understood that I do not limit myself to the showing made by thesaid drawing and description, as I may adopt variations of the preferredform within the scope of my invention as set forth in the claims. 1

Referring to the drawing: 7

Fig. 1 is a perspective view showing a portion of a conventionalhouseholdsink and the splashand drain-boards associated therewith. The

splashand. drain-boards, are. constructed in ac-- cordance with theprinciples of the present invention.

Fig. 2 is a perspective view of one of the elements viewed from theback, a portion of the figure being broken away the better to disclose'5. the construction of the panel;

Fig. 3 is a perspective view similar to Fig. 2 but slightly enlarged andshowing the parts separated from each other;

Fig. 4 is an enlarged transverse sectional view, the plane of sectionbeing indicated by the line 4-4 of Fig. 2;

Fig. 5 is a similar view taken on the line 5-5 of Fig. 2; and

Fig. 6 is a similar view taken on the line B-6 of Fig. 2.

In terms of broad inclusion, the present invention comprises a finishdetail element for use in construction work, in the form of a panel ofany suitable size and shape, which panel is constructed of a sheet ofmetal to the back face of which a sheet of metal lath is integrallyjoined at closely spaced points throughout the entire area of thesheets, and suitable cementitious grouting material spread upon themetal lath in such a manner that it either entirely fills the spacebetween the metal lath and the metal sheet or develops a sufiicient keybetween the metal lath and metal sheet to anchor the grouting securelyto the assembled sheets. Preferably the metal sheet has. all or selectedones of its lateral edges deflected to provide upstanding flanges on theinner face of the sheet, thus providing a panlike construction withinwhich the metal lath and grouting are accommodated. Upon completion,therefore, the panel of the present inv vention presents a metal outerface and an inner face of hardened cementitious material such asordinary keen cement, and inasmuch as the latter unites effectually witha suitable bond such as green cement spread thereon, as a means forcausing the panel to adhere to the under structure, when the panel hasbeen mounted in the manner indicated it is as securely disposed asconventional tile. The outer face of the metal sheet may be polished,lacquered or enameled, or any suitable finish may be applied thereto,depending upon the type of installation and the finish of thesurrounding portions of the construction with which it is to harmonize.50

More specifically described, the constructional finish detail element ofthe present invention comprises a sheet H of suitable metal, such asstainless steel, or, in the event that such finish as enamel or paint isto be employed, of ordinary sheet iron. Flanges l2, I3 are formed aboutthe periphery of the sheet I I by bending the edges to lie substantiallyperpendicular to the plane of the sheet, these upstanding flanges l2, l3being formed on that face of the sheet II which is to be the back, orthe inner face thereof. Hence this flanged sheet H is in the form of apan indicated in its entirety at [4.

Within the hollow side of the pan M, i. e., against the inner face andlying between the flanges i2, i3 is. a sheet I5 of metal lath,preferably coextensive with that portion of the sheet II from which theflanges I2, l3 extend. The metal lath I6 is united integrally with thesheet II as by spot welding, such welds occurring at short intervalsthroughout the entire area of the sheet--say every three or four inches,both longitudinally and laterally.

Whereas metal lath it of any suitable design may be employed, that whichI have found most desirable for the present use is of expanded metal andcomprises a plurality of longitudinally extending V-shaped troughs ii,the crests l8 of which are in contact with the inner face of the metalsheet H. These troughs H are separated from each other a materialdistance but are joined by a large number of spaced webs l9 or ribbonswhich serve to unite the entire sheet I6 of metal lath in an integralunit but to leave a large number of apertures therethrough, throughwhich cementitious material can be forced either to embed the metal lathcompletely therein or to form a suitable key of cementitious materialbetween the metal lath l6 and the metal sheet I l This ceinentitiouslath or grouting 2| is applied while in plastic and usually wet form,hence I have found it desirable at least under some circumstances toprovide a protective coating upon at least those portions of the elementwith which the grouting 2| comes in contact. This is most easilyaccomplished by dipping the entire assembled and welded sheets H and itin a bath of enamel, which subsequently hardens and provides asubstantially impervious coating to prevent rusting or corrosion evenafter the bonding material 2! has been applied.

The flanges l2, l3 serve as guides or stops to determine the quantity ofcementitious material 21 to be applied within the pan i i, inasmuch asin its preferred construction the hollow back side of the panel iscompletely filled with this cementi tious material. When it hashardened, the exposed surface of this cementitious material isaltogether suitable to receive bonding material such as keen cementsimilar to that used in setting tile, whereby the completed panel can bemounted upon the under structure; it being understood, of course, thatthat under structure has previously been prepared by being coated with asuitable sheet of cement or similar material, as when preparing for thereception of ordinary tile.

It becomes apparent, therefore, that the present invention provides ametal panel of any suitable size and shape. It is recognized that it isnot new to employ metal panels as finish detail in many types ofconstruction, viz.: stainless steel and monel splashand drain-boards andthe metal sheath commonly used for decorative effects upon such forms.

Previously, however, it has been possible to support such metal sheetsonly along their edges. Particularly in the case of sheet metaldrainboards this limitation is definitely disadvantageous because of thetendency for the metal, being unattached to the supporting structureexcept at its edges, to warp, sag or buckle, thus becoming separatedfrom the supporting structure, spoiling the otherwise smooth outersurface and hence becoming definitely unsightly. In the case ofdrain-boards, this tendency is especially unfortunate because wheneverheat is applied to the panel, as when a hot receptacle is placedthereon, the metal will swell where the heat is applied, thus forming ablister or swelling which never returns to its original fiat condition,even when cooled to its original temperature. This disadvantage isentirely overcome by the present invention by the spot welding by meansof which the metal lath is integrally united with the back face of themetal panel at such short intervals throughout their entire co-extensivearea.

Whereas the welding causes discoloration of the outer face of the sheetmetal H, and in some instances actual swelling, this presents nodifficulty inasmuch as the finishing of the outer face is not performeduntil after the welding has been completed and usually until after allthe other steps in the process of manufacture. of the panel arefinished, thus leaving the outer face of the completed panel. perfectlysmooth and devoid of any defect in respect to discoloration. The outerface can be finished in any manner. If a stainless steel or Monelmetaldrainor splash-board is being formed, the outer face of thefinished panel will be left polished but without any coating. However,if it is desired to simulate a tile construction, the outer face of. thepanel can be enameled and preferably then baked to provide the morebeautiful and durable surface. Any suitable pigment may be employed inthe glaze when enameling, so that the panel of the present invention canbe used in conjunction with any type of construction and caused toharmonize with its surroundings just as. satisfacorily as in the case ofthe more conventional tile.

The panel of the present invention is possessed of a great advantageover tile, however, in that each construction unit such as eachdrain-board, each splash-board, or each wall of a bathroom or of ashower stall is of one single piece. Obviously this is a much moredesirable construction than conventional tile, in which each element. ofconstruction is made up of a large number of tiles bonded together bygrouting. This grouting has the tendency to become chipped, thus notonly becoming relatively unsightly but also developing a highlyunsanitary condition because of. the difficulty of keeping the grooveswhich develop when the grouting chips out free from accumulated matter.

Fig. 1 illustrates the manner of installation of the constructionalfinish detail element of the present invention. Here it is illustratedas forming the splash-board 26 and drain-board '21 for a conventionalhousehold sink 28. It should be noted that each of the boards 26, 21 isof one single piece. Each is made of proper size to fit into the desiredlocation and then mounted in operative position in. accordance with thedescription hereinabove. Such assembly yields a thoroughly waterproofand sanitary construction having all the advantages, both from thestandpoint of serviceability and decorative effect, of conventionaltile, but none of the disadvantages.

I claim:

1. In a surfacing panel for building construction, a metal sheet, andmeans for attaching said sheet rigidly to a supporting structure, saidattachlng means comprising a sheet of metal lath welded totheinner faceof said sheet at closely spaced spots throughout the area thereof, andcementitious material applied to said inner face of said metal sheet andembedding said metal lath within said cementitious material, the exposedface of said cementitious material being adapted to receive bondingmaterial for fastening said panel to said supporting structure.

2. In a surfacing panel for building construction, a metal sheet, andmeans for attaching said sheet rigidly to a supporting structure, saidattaching means comprising a sheet of metal lath welded to the innerface of said sheet at closely spaced spots throughout the area thereof,and cementitious material applied to said inner face of said metal sheetand embedding said metal lath within said cementitious material, edgesof said metal sheet being bent up to present a pan construction withinwhich said cementitious material is confined, and the exposed face ofsaid cementitious material being adapted to receive bonding material forfastening said panel to said supporting structure.

3. In a surfacing panel for building construction, a metal sheet, meansfor attaching said sheet rigidly to a supporting structure, saidattaching means comprising a sheet of metal lath Welded to the innerface of said sheet at closely spaced spots throughout the area thereof,and cementitious material applied to the inner face of said metal sheetand embedding said metal lath within said cementitious material, theexposed face of said cementitious material being adapted to receivebonding material for fastening said panel to said supporting structure,and finish applied to the other face of said metal sheet.

4. In a panel construction of the character described, a metal sheet andmeans for attaching said sheet rigidly to a supporting structurecomprising metal lath fastened to a face of said sheet, a protectivecoating covering said metal lath and the associated face of said sheet,and cementitious material applied to said face of said sheet andembedding said metal lath therein.

ARTHUR DOI-IERTY.

